EP3516130B1

EP3516130B1 - Resilient flooring product and methods of making same

Info

Publication number: EP3516130B1
Application number: EP17853799.9A
Authority: EP
Inventors: Tom Odum; Jeff Wright; Jay VECSEY
Original assignee: Shaw Industries Group Inc
Current assignee: Shaw Industries Group Inc
Priority date: 2016-09-23
Filing date: 2017-09-20
Publication date: 2023-05-10
Anticipated expiration: 2037-09-20
Also published as: KR20190086435A; US10914080B2; KR102513809B1; EP3516130A1; US20220364372A1; US20230332417A1; CN109863276B; US20210123245A1; CN109863276A; US11725397B2; US11434647B2; US20180163413A1; US12203276B2; EP3516130A4; WO2018057602A1

Description

FIELD

The invention relates to a resilient floor covering, and more particularly, to a resilient floor covering utilizing digitally printed images.

BACKGROUND

Conventional resilient floor coverings are typically produced in the form of a continuous sheet or in the form of a tile or a plank. Resilient sheet flooring typically comprises a bottom, a thermally stable, base or a matte layer coated with one or more layers of similarly formulated polymeric compounds. For aesthetic purposes, an ink layer is also typically disposed between the polymeric layers, and the polymeric layers may optionally be chemically or mechanically embossed. Similarly, resilient tile flooring is typically formed as a composite laminated structure having a base layer, a decorative layer applied on top of the base layer, a protective film layer disposed on top of the decorative layer, and a top coat disposed on top of the protective film layer. For aesthetic purposes, the tile may also be mechanically embossed to impart a desired surface texture or pattern.
Traditionally resilient floor coverings use images printed on films via rotogravure and offset printing methods. One of the major drawbacks in using rotogravure or offset printing methods is the significant capital investments necessary to prepare a rotary printing press, batch and test ink colors, as well as maintain the entire film in a registry. Digital printing, on the other hand, offers a considerably simpler solution by allowing near instant results of images with small run sizes and millions of color variations.
However, use of digital printing introduces additional challenges for the resilient floor coverings manufacturing industry. Specifically, the Ultra Violet (UV) cured inks that are often used in the digital printing to form an ink layer, in fact, do not allow lamination of any additional polymer layers on the top of this ink layer, and thus, prevent formation of a composite laminated structure of the resilient floor coverings.
WO2016/134243 relates to a resilient floor covering made from non-vinyl materials comprising a backing portion, a decorative portion comprising an ink layer, and a wear layer.
WO2016/113378 relates to a covering comprising a surface layer, a substrate layer attached to said surface layer, a backing layer on the bottom side of said substrate layer opposite to said surface layer, a decorative portion comprising a printed ink and a textile layer attached to the bottom side of said backing layer, characterized in that said covering further comprises a coating applied to the bottom side of said textile layer.
There remains a need for resilient floor coverings that contain a laminated structure comprising an ink layer using UV-cured inks, especially formed by digital printing, and additional layers adhered on a top of the ink layer. In other words, it would be desirable to provide a resilient floor covering that can be manufactured using UV-cured inks, especially digitally printed, wherein the formed ink layer can be easily adhered to any additional layer, such as, for example, a wear layer overlying the top of the ink layer in a manner allowing the formation of a conventional laminated structure of the resilient floor covering.
There similarly remains a need for a resilient flooring that provides high adhesive properties between an ink and a wear layer. Still further, there is a need for a method of making the same.

SUMMARY

In one aspect, disclosed herein is a resilient floor covering, as claimed in claim 1, comprising: a backing portion having a first surface and a second surface, wherein the second surface of the backing portion is opposed to the first surface of the backing portion, wherein the backing portion comprises at least one backing layer; a decorative portion having a first surface and a second surface, wherein the second surface of the decorative portion is opposed to the first surface of the decorative portion, wherein the decorative portion overlies the backing portion such that at least a portion of the second surface of the decorative portion contacts at least a portion of the first surface of the backing portion, wherein the decorative portion comprises a UV cured ink layer, and wherein the UV cured ink layer has a first surface and a second surface, and wherein the second surface of the UV cured ink layer is opposed to the first surface of the UV cured ink layer, and wherein at least a portion of the first surface of the UV cured ink layer defines at least a portion of the first surface of the decorative portion; a tie layer comprising an adhesive composition comprising a hot melt polyurethane and having a first surface and a second surface, wherein the second surface of the tie layer is opposed to the first surface of the tie layer, wherein the tie layer substantially overlies the decorative portion such that at least a portion of the second surface of the tie layer contacts and adheres to the first surface of the UV cured ink layer; and a wear layer having a first surface and a second surface, wherein the second surface of the wear layer is opposed to the first surface of the wear layer, wherein the wear layer substantially overlies the tie layer such that at least a portion of the second surface of the wear layer contacts and adheres to at least a portion of the first surface of the tie layer.
In another aspect, disclosed herein is a method for making a resilient floor covering, as claimed in claim 16, comprising: forming a composite comprising: a backing portion having a first surface and a second surface, wherein the second surface of the backing portion is opposed to the first surface of the backing portion, wherein the backing portion comprises at least one backing layer; a decorative portion having a first surface and a second surface, wherein the second surface of the decorative portion is opposed to the first surface of the decorative portion, wherein the decorative portion overlies the backing portion such that at least a portion of the second surface of the decorative portion contacts at least a portion of the first surface of the backing portion, wherein the decorative portion comprises a UV cured ink layer, and wherein the UV cured ink layer has a first surface and a second surface, and wherein the second surface of the UV cured ink layer is opposed to the first surface of the UV cured ink layer, and wherein at least a portion of the first surface of the UV cured ink layer defines at least a portion of the first surface of the decorative portion; a tie layer comprising an adhesive composition comprising a hot melt polyurethane and having a first surface and a second surface, wherein the second surface of the tie layer is opposed to the first surface of the tie layer, wherein the tie layer substantially overlies the decorative portion such that at least a portion of the second surface of the tie layer contacts and adheres to the first surface of the UV cured ink layer; and a wear layer having a first surface and a second surface, wherein the second surface of the wear layer is opposed to the first surface of the wear layer, wherein the wear layer substantially overlies the tie layer such that at least a portion of the second surface of the wear layer contacts and adheres to at least a portion of the first surface of the tie layer.
In the method as summarized above the step of forming further comprises: applying the second surface of the decorative portion onto the first surface of the backing portion; applying the second surface of the tie layer onto the first surface of the decorative portion such that the second surface of the tie layer contacts and adheres to the first surface of the UV cured ink layer; and applying the second surface of the wear layer onto the first surface of the tie layer such that the second surface of the wear layer contacts and adheres to the first surface of the tie layer.
In the method as summarized above the step of forming further comprises: applying the second surface of the decorative portion onto the first surface of the backing portion; applying the second surface of the wear layer onto the first surface of the tie layer such that the first surface of the tie layer contacts and adheres to the second surface of the wear layer; and applying the second surface of the tie layer onto the first surface of the decorative portion such that the first surface of the decorative portion contacts and adheres to the second surface of the tie layer.

BRIEF DESCRIPTION OF THE FIGURES

These and other features of the aspects of the invention described herein will become more apparent in the detailed description in which reference is made to the appended drawings wherein:

FIG. 1 depicts an exemplary structure of a resilient floor covering according to aspects of the present invention.
FIG. 2 depicts an exemplary structure of a resilient floor covering according to aspects of the present invention.
FIG. 3 depicts an exemplary manufacturing methodology for producing a resilient floor covering according to aspects of the present invention.
FIG. 4 depicts an exemplary manufacturing methodology for producing a resilient floor covering according to aspects of the present invention.
FIG. 5 depicts an exemplary manufacturing methodology for producing a resilient floor covering according to aspects of the present invention.
FIG. 6 depicts an exemplary manufacturing methodology for producing a resilient floor covering according to aspects of the present invention.

DETAILED DESCRIPTION

In this specification and in the claims that follow, reference will be made to a number of terms, which shall be defined to have the following meanings:
Throughout the description and claims of this specification the word "comprise" and other forms of the word, such as "comprising" and "comprises," means including but not limited to, and is not intended to exclude, for example, other additives, components, integers, or steps. Furthermore, it is to be understood that the terms comprise, comprising and comprises as they related to various aspects, elements and features of the disclosed invention also include the more limited aspects of "consisting essentially of" and "consisting of."
As used throughout, the singular forms "a," "an" and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a layer" can include two or more such layers unless the context indicates otherwise.
Ranges can be expressed herein as from "about" one particular value, and/or to "about" another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent "about," it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.
As used herein, the terms "optional" or "optionally" mean that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.
As used herein, the term "substantially" means that the subsequently described event or circumstance completely occurs or that the subsequently described event or circumstance generally, typically, or approximately occurs. For example, when the specification discloses that substantially all of an agent is released, a person skilled in the relevant art would readily understand that the agent need not be completely released. Rather, this term conveys to a person skilled in the relevant art that the agent need only be released to an extent that an effective amount is no longer unreleased.
As used herein, the term "digital printing" refers to a digitally controlled ejection of drops of coloring fluid that is used to position colorants in pre-defined patterns onto a surface.
As used herein, the term "UV cured inks" refers to an ink that after application is at least partially cured by exposure to UV-light. For example, and without limitation, it is understood that UV cured inks can contain photo-initiators, additives, monomer and oligomers. It is further understood that when these inks are exposed to a predetermined UV light power and/or intensity, polymerization of the polymers can occur by both a free radical and a cation curing.

A. RESILIENT FLOOR COVERING

The present invention relates to resilient floor coverings. In one aspect, the resilient floor covering is configured for placement on a floor in a selected orientation. With reference to FIG. 1 , the resilient floor covering comprises a backing portion (102), a decorative portion (104), a tie layer (106), and a wear layer (108).
The resilient floor covering comprises a backing portion having a first surface and a second surface, wherein the second surface of the backing portion is opposed to the first surface of the backing portion, and wherein the backing portion comprises at least one backing layer. In some aspects, the backing portion is configured such that the second surface of the backing portion is substantially abutting the floor in a certain orientation. The backing portion comprises at least one backing layer.
The resilient floor covering further comprises a decorative portion having a first surface and a second surface, wherein the second surface of the decorative portion is opposed to the first surface of the decorative portion. The decorative portion overlies the backing portion such that at least a portion of the second surface of the decorative portion contacts at least a portion of the first surface of the backing portion. The decorative portion comprises a UV cured ink layer. The UV cured ink layer has a first surface and a second surface, wherein the second surface of the UV cured ink layer is opposed to the first surface of the UV cured ink layer. At least a portion of the first surface of the UV cured ink layer defines at least a portion of the first surface of the decorative portion.
The resilient floor covering further comprises a tie layer comprising an adhesive composition comprising a hot melt polyurethane and having a first surface and a second surface, wherein the second surface of the tie layer is opposed to the first surface of the tie layer. The tie layer substantially overlies the decorative portion such that at least a portion of the second surface of the tie layer contacts and adheres to the first surface of the UV cured ink layer.
The resilient floor covering further comprises a wear layer having a first surface and a second surface, wherein the second surface of the wear layer is opposed to the first surface of the wear layer. The wear layer substantially overlies the tie layer such that at least a portion of the second surface of the wear layer contacts and adheres to at least a portion of the first surface of the tie layer. In still further aspects, the first surface of the wear layer can be exposed to an ambient environment. In yet other aspects, the first surface of the wear layer can further comprise a scratch layer. In still further aspects, the scratch layer can have a first surface and a second surface, wherein the second surface of the scratch layer is opposed to the first surface of the scratch layer. In still further aspects, the scratch layer overlies the wear layer such that at least a portion of the second surface of the scratch layer contacts at least a portion of the first surface of the wear layer.
In still further aspects, the resilient floor covering described herein can be in any form known in the art. In certain aspects, the resilient floor covering is a rolled good, sheet good, a tile, or a plank.

1. BACKING PORTION

The backing portion of the resilient floor covering has a first surface and a second surface, wherein the second surface is opposed to the first surface. In this aspect, the second surface of the backing portion can be configured abutting the floor when the resilient floor covering is placed in a selected orientation. The backing portion comprises at least one backing layer. In some aspects, the backing portion can comprise a single backing layer. In yet other aspects, the backing portion can comprise a plurality of backing layers. In certain aspects, when the plurality of backing layers is present, a first backing layer overlies a second backing layer that in its turn overlies a third backing layer, and so on. In certain aspects, it is contemplated that a last backing layer of the plurality of the backing layers can define the second surface of the backing portion. It is further contemplated that a first backing layer of the plurality of backing layers can define the first surface of the backing portion. In still further aspects, the at least one backing layer can comprise a single backing layer. In yet still further aspects, the at least one backing layer can comprise a plurality of backing layers.
In one aspect, the at least one backing layer of the backing portion can comprise one or more first backing layers and a secondary backing layer. For example, in a further aspect, the at least one backing layer of the backing portion can comprise a first backing layer, a second backing layer, and a secondary backing layer. In a still further aspect, the secondary backing layer can define the second surface of the backing portion, and the first and second backing layers can be configured to substantially overlie the secondary backing layer.
In an exemplary aspect, as shown FIG. 2 , in addition to wear layer (208), tie layer(s) (206), the decorative portion (204) comprising UV cured ink layer (204b) and substrate layer (204a), the one or more backing layers can be formed in the backing portion (202). These one or more backing layers can comprise a first backing layer (202a) and a second backing layer (202b). In this aspect, the first backing layer can define the first surface of the backing portion. In other exemplary aspects, the second backing layer can define the second surface of the backing portion. In yet further exemplary aspects, if the secondary backing layer (202c) is present, the secondary backing layer can define the second surface of the backing potion.
The one or more backing layers may be formed from and comprise a backing composition. For example, the first and second backing layers comprise a backing composition. The first and second backing layers can comprise the same backing composition. Alternatively, the first and second backing layers can comprise different backing compositions.
The backing portion can comprise additional layers that can be introduced therebetween the first and second backing layers. In some examples, and as shown in FIG. 2 , the backing portion can comprise a reinforcement layer (202d). The reinforcement layer can comprise a non-woven or wet-laid fiberglass scrims, as well as woven and non-woven thermoplastic fabrics (e.g. polypropylene, nylon and polyester). The reinforcement layer can comprise a fiberglass. Without wishing to be bound by a particular theory, the reinforcement layer can increase dimensional stability by reducing the chance for shrinkage or growth after installation of the flooring product.
The backing composition can comprise any backing composition known in the art. In some examples, the backing composition can comprise a polyester, a polyamide, a polyvinyl chloride, a polyolefin, a polyurethane, or any combination thereof. It is further understood, that if a combination of various polymers is present in the backing composition, the relative amount of each polymer in the composition can be any amount known in the art.
A "polyester" described herein refers to a category of polymers that contain the ester functional group in their main chain. Polyesters disclosed herein include naturally occurring chemicals, such as in the cutin of plant cuticles, as well as synthetics produced through step-growth polymerization. An unlimiting example of polyester components includes any long-chain synthetic polymer composed of at least 85% by weight of an ester of a substituted aromatic carboxylic acid, including but not restricted to substituted terephthalic units, p(-R-O-CO- C₆H₄-CO-O-)_x and parasubstituted hydroxybenzoate units, p(-R-O-CO-C₆H₄-O)_x. In certain examples, the polyester component comprises polyethylene terephthalate (PET) homopolymers and copolymers, polybutylene terephthalate (PBT) homopolymers and copolymers, and the like, including those that contain comonomers such as cyclohexanedimethanol, cyclohexanedicarboxylic acid, and the like.
A "polyamide" as utilized herein, is defined to be any long-chain polymer in which the linking functional groups are amide (-CO-NH-) linkages. The term polyamide is further defined to include copolymers, terpolymers and the like as well as homopolymers and also includes blends of two or more polyamides. An example of polyamide component includes one or more of nylon 6, nylon 66, nylon 10, nylon 612, nylon 12, nylon 11, or any combinations thereof.
A "polyolefin" disclosed herein, refers to any class of polymers produced from a simple olefin (also called an alkene with the general formula C_nH_2n) as a monomer. In some aspects, the polyolefins include, but are not limited to, polyethylene, polypropylene, both homopolymer and copolymers, poly(l-butene), poly(3-methyl-l-butene), poly(4- methyl- 1-pentene) and the like, as well as combinations or mixtures of two or more of the foregoing.
A "polyurethane" described herein refers to any class of polymers composed of a chain of organic units joined by carbamate (urethane, R-O-CO-NR-R) links.
The backing composition can comprise, for example and without limitation, low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), ethylene methacrylate (EMA), ethylene vinyl acetate (EVA), polyethylene-polypropylene (PE-PP) rubber, conventional thermoplastic elastomers (TPEs), conventional thermoplastic olefins (TPOs), alpha-olefin polyethylene co-polymers, polyethylene terephthalate (PET), ethylene butyl acrylate (EBA), and the like. In a still further aspect, the backing composition comprises an ethylene-octene copolymer.
As disclosed in United States Patent Application 11/963,263 , the backing composition can comprise substantially linear ethylene polymers and homogeneously branched linear ethylene polymers (i.e., homogeneously branched ethylene polymers), which offer low solidification temperatures, good adhesion to polypropylene, and low modulus relative to conventional ethylene polymers such as low density polyethylene (LDPE), heterogeneously branched linear low density polyethylene (LLDPE), high density polyethylene (HDPE), and heterogeneously branched ultra low density polyethylene (ULDPE). Exemplary backing layers formed from the disclosed homogeneously branched ethylene polymers are shown in the figures as first or second backing layers.
Exemplary backing compositions are disclosed in United States Patent Application No 15/048,215 .
Any disclosed herein backing compositions can be used alone or can be blended or mixed with one or more synthetic or natural polymeric materials. For examples, suitable polymers for blending or mixing with homogeneously branched ethylene polymers used in the present invention include, but are not limited to, another homogeneously branched ethylene polymer, low density polyethylene, heterogeneously branched LLDPE, heterogeneously branched ULDPE, medium density polyethylene, high density polyethylene, grafted polyethylene (e.g. a maleic anhydride extrusion grafted heterogeneously branched linear low polyethylene or a maleic anhydride extrusion grafted homogeneously branched ultra-low density polyethylene), ethylene acrylic acid copolymer, ethylene vinyl acetate copolymer, ethylene ethyl acrylate copolymer, polystyrene, polypropylene, polyester, polyurethane, polybutylene, polyamide, polycarbonate, rubbers, ethylene propylene polymers, ethylene styrene polymers, styrene block copolymers, and vulcanates.
The backing composition used to prepare at least one of the backing layers of the present invention can comprise a filler component. As would be recognized by one of ordinary skill in the art, the type of filler used can be selected on the basis of the desired physical properties of the final product. Exemplary fillers can include, for example and without limitation, calcium carbonate, barium sulfate, barite, glass fiber and powder, metal powder, alumina, hydrated alumina, clay, magnesium carbonate, calcium sulfate, silica or glass, fumed silica, talc, carbon black or graphite, fly ash, cement dust, feldspar, nepheline, magnesium oxide, zinc oxide, aluminum silicate, calcium silicate, titanium dioxide, titanates, wood flour, glass microspheres, chalk, and mixtures thereof. Additional fillers that can be used include graphite fiber, silica/glass, wollastonite, crushed glass cullet, kaolin, mica, recycled fines, fiberglass, diatomaceous earth, lime, and mixtures thereof. An exemplary filler is fly ash, such as, for example and without limitation, Celceram^™ fly ash filler PV20A (a calcium aluminum silicate available from Boral). The backing composition can comprise post-industrial carpet and/or post-consumer carpet material. The backing composition can comprise composites of post-industrial carpet and/or composites of post-consumer carpet. The glass filler may be glass fines or crushed glass cullet. The fly ash can be coal fly ash.
The backing composition can comprise a filler in an amount of from about 65% to about 95% by weight, including exemplary filler weight % values of 70 % by weight, 71 % by weight, 72 % by weight, 73 % by weight, 74 % by weight 75 % by weight, 76 % by weight, 77 % by weight, 78 % by weight, 79 % by weight, 80 % by weight, 85 % by weight, 90 % by weight, and 94 % by weight. The backing composition can comprise a filler in an amount in a range derived from any two of the above listed exemplary weight percentage values. For example, the backing composition can comprise a filler in a range of from about 70% to about 90% by weight, or from about 75% to about 85% by weight. The backing composition may comprise at least 80% filled polyethylene composition. For example, the backing composition can comprise at least an 80% filled ethylene-octene copolymer composition.
The backing composition can optionally comprise one or more additives, for example and without limitation, tacifiers, processing agents, foaming agents, plasticizers, or the like. The additive can comprise a hydrocarbon resin. The hydrocarbon resin can be PICCOTAC^™ 1115, which is manufactured by Eastman Chemical, and which is a relatively high molecular weight, aliphatic C5 resin derived from dienes and other reactive olefin.
The backing composition can optionally include maleic anhydride grafts wherein maleic anhydride is grafted onto an ethylene polymer at a concentration of about 0.1 to about 5.0 weight percent, preferably about 1 to about 2 weight percent. An exemplary composition for forming a maleic anhydride graft is Amplify^® GR 204 resin available from Dow Chemicals.
The secondary backing layer, when present, can comprise, for example and without limitation, oriented polypropylene (OPP), woven polyethylene (PE), nonwoven polyethylene (PE), woven polypropylene (PP), nonwoven polypropylene (PP), woven polyethylene terephthalate (PET), nonwoven polyethylene terephthalate (PET), woven nylon, nonwoven nylon, and the like. The secondary backing layer can comprise nonwoven fiberglass, woven fiberglass, recycled fiber shoddy, polyethylene terephthalate (PET) film, polypropylene (PP) film, polyethylene (PE) film, linear low-density polyethylene (LLDPE) film, polystyrene copolymer, polypropylene-polyethylene (PP-PE) copolymer, polyolefin elastomer, polyvinyl chloride, or polyurethane, or a combination thereof. The secondary backing layer can comprise an embossed pattern.
The fiberglass layer, when present, can comprise a fiberglass mat. The fiberglass layer can comprise a weight of from about 20 to about 90 g/m², including exemplary values of about 30, 40, 50, 60, 70, or 80 g/m². The fiberglass mat can allow for increased binder polymer saturation and, thus, a reduction in the chance for delamination from highly filled first and second backing layers. Beneficially, a thinner fiberglass mat can reduce the overall weight of the final flooring product and is less expensive than thicker fiberglass.

2. DECORATIVE PORTION

The resilient floor covering comprises a decorative portion. The decorative portion has a first surface and a second surface. The second surface of the decorative portion is opposed to the first surface of the decorative portion. The first surface of the backing portion contacts the second surface of the decorative portion.
The decorative portion comprises a UV cured ink layer. The UV cured ink layer has a first surface and a second surface, wherein the second surface of the UV cured ink layer is opposed to the first surface of the UV cured ink layer. At least a portion of the first surface of the UV cured ink layer defines at least a portion of the first surface of the decorative portion. Optionally, the UV cured ink layer can also define the second surface of the decorative portion.
In yet other aspects, the decorative layer can further comprise a substrate layer. In certain aspects, the substrate layer has a first surface and a second surface, wherein the second surface of the substrate layer is opposed to the first surface of the substrate layer. In still further aspects, the UV cured ink layer can be applied to the first surface of the substrate layer. Optionally, the UV cured ink layer can be applied to the second surface of the substrate layer. In certain aspects, the second surface of the substrate layer can define the second surface of the decorative portion overlying the first surface of the backing layer. Yet in other aspects, the first surface of the substrate layer can define the second surface of the decorative portion overlying the first surface of the backing layer.
It is contemplated that the UV cured ink layer can be applied either directly or indirectly thereto the first surface of the substrate layer. The ink layer is a UV cured ink layer.
It is understood that UV-cured inks can comprise photo-initiators, pigments, additives, monomers and oligomers of various polymers, and the like. In some exemplary aspects, the UV-cured inks can comprise, without limitation, (5-ethyl-1,3-dioxan-5yl)methyl acrylate, 2-phenoxyethyl acrylate; 1-vinylhexahydro-2H-azepin-2-one, substituted phosphine oxide, thrimethylolpropane triacrylate, phenyl bis (2,4 6-trimethylbenzoyl)phosphine oxide, epoxy acrylate oligomer, diacrylate monomer, multifunctional monomers, amine modified acrylate oligomer, 1-vinylhexahydro-2H-asepin-2-one, diacrylate oligomers, benzophenone, triacryalte monomers, 1-hydroxy-cyclohexylphenyl-ketone, 2 hydroxy-2-methylpropiophenone, and the like.
The UV cured ink layer can be applied to the substrate layer by any conventional printing means, which can include, without limitation, rotogravure printing, flexography printing, lithography printing, offset-lithography printing, relief printing, thermography printing, thermal sublimation printing, dye-sublimation printing, heat-transfer printing, digital printing, and the like.
In still further aspects, the UV cured ink layer can be applied by digital printing. In an exemplary aspect, the UV cured ink layer can comprise inks and pigments manufactured by Collins Inks, INX Inks, Durst, HP, EFI, Sun Chemical, or Tiger. The UV cured ink layer can be digitally printed utilizing digital printers manufactured by Cefla, Durst, Hymmen, EFI, Barbaran or Inca.
In certain aspects, the formed UV cured ink layer can be a continuous layer that covers substantially all of the first surface of the substrate. In yet other aspects, the formed UV cured ink layer can be a discontinuous layer that covers only a portion of the first surface of the substrate. The UV cured ink layer can have any desired aesthetic appearance, such as, for example and without limitation, the appearance of simulated hardwood or ceramic flooring.
In certain aspects, the substrate layer can comprise at least one of polyvinyl chloride (PVC), whitened PVC, opaque PVC, oriented polypropylene (OPP), polyolefin (PO), woven polyethylene (PE), nonwoven PE, woven polypropylene (PP), nonwoven PP, woven PET, nonwoven PET, woven nylon, nonwoven nylon, conventional papers, conventional foils, or foiled oriented polypropylene.
The substrate layer can comprise a transparent PVC. In yet other aspects, the substrate layer comprises a whitened PVC. In still further aspects, the substrate layer comprises an opaque PVC. It is understood that if whitened substrate is used, any whitening agent known in the art can be utilized. It is further understood that the whitening agent disclosed herein can comprise inorganic and/or organic compounds. The whitening agent can be a fluorescent whitening agent. In one embodiment, the whitening chemistry comprises titanium dioxide, zinc dioxide, and the like. The whitening can be also achieved by cavitation.
In further aspects, the substrate layer can comprise one or more of a heat stabilized biaxially-oriented PET (BoPET), amorphous PET (aPET), recycled PET (rPET), polyethylene terephthlate glycol-modified (PETG), polyolefin, cyclic olefin copolymer (COC), cyclic olefin polymer (COP), polyvinylidene fluoride (PVDF), polylactic acid (PLA) copolymers, nylon, cellulose acetate, poly(methyl methacrylate) (PMMA), thermoplastic polyurethane (TPU), thermoplastic elastomers (TPS), polycarbonate, polyethylene (PE), or a copolymer thereof.
In certain aspects, the substrate layer has a thickness from about 1 mil (25µm) to about 20 mil (510µm), including exemplary values of about 2 mil (51µm), about 3 mil (76µm), about 4 mil (100µm), about 5 mil (130µm), about 6 mil (150µm), about 7 mil (180µm), about 8 mil (200µm), about 9 mil (230µm), about 10 mil (250µm), about 11 mil (280µm), about 12 mil (300µm), about 13 mil (330µm), about 14 mil (360µm), about 15 mil (380µm), about 16 mil (400µm), about 17 mil (430µm), about 18 mil (460µm), and about 19 mil (480µm). In still further aspects, the substrate layer can have any thickness in a range derived from any two of the above listed exemplary values. For example, the substrate layer can comprise a thickness in a range of from about 1 mil (25µm) to about 5 mil (130µm), or from about 3 mil (76µm) to about 7 mil (180µm). In still further aspects, the substrate layer can be a film.

3. TIE LAYER

The resilient floor covering further comprises a tie layer. The tie layer can comprise at least one tie layer. The tie layer can comprise a plurality of tie layers. The tie layer comprises an adhesive composition comprising a hot melt polyurethane. The tie layer has a first surface and a second surface. The second surface of the tie layer is opposed to the first surface of the tie layer. The tie layer substantially overlies the decorative portion such that at least a portion of the second surface of the tie layer contacts and adheres to the first surface of the UV cured ink layer.
It is understood that the tie layer can be positioned between opposing layers of the resilient floor covering to enhance or facilitate a bond between otherwise dissimilar or incompatible materials that form the otherwise opposing layers of the floor covering together. As one skilled in the art will appreciate, such dissimilar materials can have inherent properties that negatively affect the ability of the respective materials to bond or otherwise adhere to each other.
In certain aspects, and without wishing to be bound by any theory, the adhesive compositions of the tie layer described herein demonstrate improved adhesion properties when the tie layer is attached to a UV-cured inks. Even further, since the wear layer described herein is further adhered to the tie layer overlying the ink layer, strong adhesion is achieved between all three disclosed layers. The tie layer can be first adhered to the wear layer and then adhered to the ink layer. The tie layers described herein are capable of overcoming common drawbacks of the UV-cured inks that do not allow lamination of any additional polymer layers on the top of this ink layer. As illustrated in the performance properties described below, the wear layer laminated to the ink layer manufactured with UV-cured inks, when the tie layer is disposed therebetween, exhibits high pull and adhesion values.
In certain aspects, the tie layer has a thickness of about 0.1 mil (2.5µm) to about 5 mil (130µm), including exemplary values of about 0.5 mil (13µm), about 1 mil (25µm), about 1.5 mil (38µm), about 2 mil (51µm), about 2.5 mil (64µm), about 3 mil (76µm), about 3.5 mil (89µm), about 4 mil (100µm), and about 4.5 mil (110µm). In still further aspects, the tie layer can have any thickness in a range derived from any two of the above listed exemplary values. For example, the tie layer can comprise a thickness in a range of from about 0.5 mil (13µm) to about 4 mil (100µm), or from about 0.1 mil (2.5µm) to about 3 mil (76µm).
The tie layer may have a weight of about 1 g/ft² (11 g/m²) to about 15 g/ft² (160 g/m²), including exemplary values of about 2 g/ft² (22 g/m²), about 3 g/ft² (32 g/m²), about 4 g/ft² (43 g/m²), about 5 g/ft² (54 g/m²) , about 6 g/ft² (65 g/m²), about 7 g/ft² (75 g/m²), about 8 g/ft² (86 g/m²), about 9 g/ft² (97 g/m²), about 10 g/ft² (110 g/m²), about 11 g/ft² (120 g/m²), about 12 g/ft² (130 g/m²), about 13 g/ft² (140 g/m²), and about 14 g/ft² (150 g/m²). The tie layer may have any weight that falls in a range derived from any two of the above listed exemplary values. For example, the tie layer can have a weight in a range of from about 2 g/ft² (22 g/m²) to about 12 g/ft² (130 g/m²), or from about 4 g/ft² (43g/m²) to about 15 g/ft² (160 g/m²).
At least one tie layer can comprise Entira^™ modifiers and additives, such as, for example and without limitation, Entira^™ Coat 100 modifier and additive manufactured by E.I. du Pont de Nemours and Company, Inc. The at least one tie layer can comprise water borne coating primers, including, for example and without limitation, G-680 Primer manufactured by Mica Corporation. One or more of the opposing layers may be pretreated with at least one of: corona, plasma, ion flame, alcohol, ozone, UV, or primer coating prior to positioning the one or more tie layer.

4. WEAR LAYER

The resilient floor covering comprises a wear layer. The wear layer has a first surface and a second surface. The second surface of the wear layer is opposed to the first surface of the wear layer. The wear layer substantially overlies the tie layer such that at least a portion of the second surface of the wear layer contacts and adheres to at least a portion of the first surface of the tie layer.
The first surface of the wear layer can be configured for exposure to an ambient environment.
The wear layer can be heat laminated to the decorative layer with using a tie layer as an adhesive.
In one aspect, the wear layer can comprise, for example and without limitation, conventional ionomers, polyethylene terephthalate (PET), polyurethane, polypropylene, polytrimethylene terephthalate (PTT), nylon 6, nylon 6,6, polyvinyl chloride (PVC), and the like. The wear layer can comprise surlyn resin, such as, for example and without limitation, Surlyn^® 1706 resin, manufactured by E.I. du Pont de Nemours and Company, Inc. In a still further aspect, the wear layer can comprise heat stabilized biaxially-oriented PET (BoPET), amorphous PET (aPET), recycled PET (rPET), polyethylene terephthalate glycol-modified (PETG), polyolefin, cyclic olefin copolymer (COC), cyclic olefin polymer (COP), polyvinylidene fluoride (PVDF), polylactic acid (PLA) copolymers, nylon, cellulose acetate, poly(methyl methacrylate) (PMMA), thermoplastic polyurethane (TPU), thermoplastic elastomers (TPE), polycarbonate, polyethylene (PE), high density polyethylene (HDPE), low density polyethylene (LDPE), or a copolymer thereof.
In some aspects, the wear layer is substantially transparent. In other aspects, the wear layer is substantially opaque.
In a yet further aspect, the wear layer can have a thickness in the range of from about 4 mil (100µm) to about 30 mil (760µm), including exemplary thickness ranges of from about 4 (100µm) to about 8 mil (200µm), about 9 (230µm) to about 14 mil (360µm), or about 16 (410µm) to about 30 mil (760µm). In a still further aspect, the thickness can be in a range derived from any of the above listed exemplary values. For example, the thickness can in the range of about 4 mil (100µm) to about 9 mil (230µm), or from 4 mil (100µm) to about 16 mil (410µm). The wear layer may be embossed with a desired texture pattern.
It is contemplated that the invention allows overcoming known drawbacks of the wear layer adhesion to the ink layer. Specifically, the wear layer of the current invention is demonstrated to be strongly adhered to the ink layer by use of the tie layer. Without being bound by any theory, it is contemplated that the tie layer of the present invention improves a compatibility of the two incompatible layers: the ink layer and the wear layer. In the aspects of the present invention the tie layer allows to bond otherwise dissimilar materials that form the otherwise opposing layers of the floor covering together.
In various aspects, the first surface of the wear layer can further comprise a scratch layer. The scratch layer can comprise polyurethane, or acrylate, or a combination thereof. The scratch layer can comprise a mixture of reactive monomers and oligomers. The scratch layer can comprise functionalized monomers, for example, and without limitation, difunctional and multifunctional monomers. The scratch layer can comprise at least one photoinitiator, or other component to catalyze a reaction among materials present in the scratch layer. The scratch layer can comprise a blend of epoxy acrylate oligomers with difunctional and multifunctional monomers. In still further aspects, the scratch layer is UV-cured scratch layer.
The scratch layer can comprise a surface hardening agent. The surface hardening agent can comprise aluminate, alumina, acrylic beads, silica, glass spheres, sol gel alumina, nylon Orgasol, MF silica Optbeads, polyethylene dispersion, silyl acrylic set wet particles, wollastonite, clay, silyl acrylic polysiloxane, sodium silicate, polyvinylidene difluoride (PVDF), silicon carbide, quartz, diamond dust, or a combination thereof. The surface hardening agent can be alumina, silica, or a combination thereof.
The scratch layer can have a thickness in the range of from about 0.25 (6.4 µm) to about 3 mils (76µm), including exemplary ranges of from about 0.50 (13µm) to about 1.25 mils (32µm), and 0.50 (13µm) to about 2.25 mils (57µm). The surface hardening agent can be present in an amount in the range of from about 0.25 weight % to about 15 weight % based upon the total weight of the scratch layer, including exemplary ranges of from about 2 weight % to about 3 weight %, and about 2 weight % to about 10 weight % based upon the total weight of the scratch layer. The surface hardening agent can be present in an amount less than or equal to 10 weight %, for example, less than about 9, 8, 7, 6, 5, 4, 3, 2, or 1 weight % based upon the total weight of the scratch layer. The surface hardening agent can comprise particulate material having an average particle size less than or equal to 20 microns, for example, less than or equal to about 15, 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1 micron. The scratch layer can be adhered to an underlying wear layer portion by a primer coating layer. The primer coating layer can have a thickness in the range of from about 0.25 (6.4µm) to about 1 mil (25µm), for example, from about 0.40 (10µm) to about 0.6 mil (15µm).

5. BALANCING LAYER

The resilient floor covering can optionally comprise at least one balancing layer. The at least one balancing layer can be positioned between opposing layers of the resilient floor covering to provide support, for example, to the backing portion. The at least one balancing layer can be positioned on bottom surface of the flooring product.
The at least one balancing layer can comprise oriented polypropylene (OPP), woven polyethylene (PE), nonwoven polyethylene (PE), woven polypropylene (PP), nonwoven polypropylene (PP), woven polyethylene terephthalate (PET), nonwoven polyethylene terephthalate (PET), woven nylon, nonwoven nylon, nonwoven fiberglass, woven fiberglass, recycled fiber shoddy, or a combination thereof.

6. PROPERTIES OF RESILIENT FLOOR COVERINGS

The resilient floor coverings of the present invention exhibit improved physical and mechanical properties.
The wear layer can exhibit a pull value greater than about 3 pounds (1.4 kg), greater than about 3.5 pounds (1.6 kg), greater than about 4 pounds (1.8 kg), greater than about 4.5 pounds (2.0 kg), greater than about 5 pounds (2.3 kg), greater than about 5.5pounds (2.5 kg), greater than about 6 pounds (2.7 kg), greater than about 6.5 pounds (2.9 kg), or greater than about 7 pounds (3.2 kg) as determined by ASTM 3936 with 1" (2.5cm) by 6" (16cm) strip pulled at a rate of 2"/min (5.1 cm/min) for a pull distance of 2" (5.1cm).
The wear layer can exhibit an abrasion resistance greater than 5,000 cycles when measured according to ASTM D3884 under testing conditions comprising an H18 wheel, 1,000 gram load, and clean each 300 cycles, including exemplary abrasion resistances of greater than 5,000 cycles, greater than 10,000 cycles, or greater than 20,000 cycles when measured according to ASTM D3884 under testing conditions comprising an H18 wheel, 1,000 gram load, and clean each 300 cycles.
The scratch layer in combination with the wear layer can exhibit an abrasion resistance greater than 5,000 cycles when measured according to ASTM D3884 under testing conditions comprising an H18 wheel, 1,000 gram load, and clean each 300 cycles, including exemplary abrasion resistances of greater than 5,000 cycles, greater than 10,000 cycles, or greater than 20,000 cycles when measured according to ASTM D3884 under testing conditions comprising an H18 wheel, 1,000 gram load, and clean each 300 cycles.
The scratch layer can exhibit an abrasion resistance in the range of from about 100 cycles to about 500 cycles when measured according to ASTM D3884 under testing conditions comprising an H18 wheel, 1,000 gram load, and clean each 300 cycles, including exemplary abrasion resistances ranges of from about 100 cycles to about 400 cycles, or from about 200 cycles to about 300 cycles when measured according to ASTM D3884 under testing conditions comprising an H18 wheel, 1,000 gram load, and clean each 300 cycles.
The exposed first surface of the wear layer can exhibit a micro-scratch resistance characterized by of a gloss change rating in the range of 1 to 3 when measured pursuant to Martindale Test EN 16094-2012 Test A (MSR-A) or Test B (MSR-B) visual assessment of surface scratching.
The scratch layer can exhibit a heat stability of less than about 12 average Delta E's as determined by ASTM F1514 or ASTM F1515, for example, less than about 8 average Delta E's as determined by ASTM F1514 or ASTM F1515.
The scratch layer can exhibit a coating adhesion value in the range of from 4B to 5B as measured according to ASTM-D3359-02 Type B. In a further example, the scratch layer exhibits a gloss level in the range of from 5 to 50 as measured with a BYK Gardner Micro-Gloss 60 degree instrument. In a still further example, the scratch layer exhibits a gloss level in the range of from 6 to 30 as measured with a BYK Gardner Micro-Gloss 60 degree instrument.
In a further example, the scratch layer can exhibit a micro-scratch resistance characterized by a gloss change rating in the range of 1 to 3 when measured pursuant to Martindale Test EN 16094-2012 Test A (MSR-A). The scratch layer can exhibit a micro-scratch resistance characterized by of a gloss change rating in the range of 1 to 3 when measured pursuant to Martindale Test EN 16094-2012 Test B (MSR-B).
The disclosed resilient floor coverings can exhibit a static load limit indentation depth in the range of from about 0 inches (0cm) to about 0.09 inches (0.23cm) as measured pursuant to ASTM F970 under conditions of: 250 lb. (110 kg) static load for 24 hours, recover of 24 hours, and 1.125 inch (2.858cm) outside diameter probe, including exemplary static load limit indentation depth ranges of from about 0 inches (0cm) to about 0.07 inches (0.18cm), or from about 0 inches (0cm) to about 0.05 inches (0.13cm) as measured pursuant to ASTM F970 under conditions of: 250 lb. (110 kg) static load for 24 hours, recover of 24 hours, and 1.125 inch (2.858cm) outside diameter probe.
The disclosed resilient floor coverings can exhibit a short term residual indentation depth in the range of from 0 inches (0cm) to 0.09 inches (0.23cm) as measured pursuant to ASTM F1914 under conditions of: 140 lb. (64kg) load for 10 minutes, recover of 60 minutes, including exemplary short term residual indentation depth ranges of from about 0 inches (0cm) to about 0.07 inches (0.18cm) , or from about 0 inches (0cm) to about 0.05 inches (0.13 cm) as measured pursuant to ASTM F1914 under conditions of: 140 lb. (64kg) load for 10 minutes, recover of 60 minutes.
The disclosed resilient floor coverings can exhibit a critical radiant flux of a class 2 flame spread as measured pursuant to ASTM-E648. The disclosed resilient floor coverings can exhibit a critical radiant flux of a class 1 flame spread as measured pursuant to ASTM-E648.
The disclosed resilient floor coverings can exhibit a dimensional stability variation of less than about 0.17% as determined by ASTM F2199-0 at 82 °C and 24 hr, including dimensional stability values of less than about 0.15% or less than about 0.10% as determined by ASTM F2199-0 at 82 °C and 24 hr. The disclosed resilient floor coverings can exhibit a dimensional stability characterized by an amount of doming or curling in the range of from 0 (0cm) to no more than 3/32" of an inch (0.24 cm) when subjected to test conditions of ASTM F2199-0 at 82 °C and after 24 hr. In a still further aspect, the dimensional stability is characterized by an amount of doming or curling of less than about 3/32" of an inch (0.24 cm) when subjected to test conditions of ASTM F2199-0 at 82 °C and after 24 hr, for example, less than about 1/16" of an inch (0.16 cm) when subjected to test conditions of ASTM F2199-0 at 82 °C and after 24 hr.

B. METHODS OF MAKING

In various aspects, the present disclosure also provides methods of making the resilient floor coverings described herein. The method of making the resilient floor coverings described herein comprises forming a composite comprising: a backing portion having a first surface and a second surface, wherein the second surface of the backing portion is opposed to the first surface of the backing portion, wherein the backing portion comprises at least one backing layer, a decorative portion having a first surface and a second surface, wherein the second surface of the decorative portion is opposed to the first surface of the decorative portion, wherein the decorative portion overlies the backing portion such that at least a portion of the second surface of the decorative portion contacts at least a portion of the first surface of the backing portion, wherein the decorative portion comprises a UV cured ink layer, and wherein the UV cured ink layer has a first surface and a second surface, and wherein the second surface of the UV cured ink layer is opposed to the first surface of the UV cured ink layer, and wherein at least a portion of the first surface of the UV cured ink layer defines at least a portion of the first surface of the decorative portion; a tie layer comprising an adhesive composition comprising a hot melt polyurethane and having a first surface and a second surface, wherein the second surface of the tie layer is opposed to the first surface of the tie layer, wherein the tie layer substantially overlies the decorative portion such that at least a portion of the second surface of the tie layer contacts and adheres to the first surface of the UV cured ink layer; and a wear layer having a first surface and a second surface, wherein the second surface of the wear layer is opposed to the first surface of the wear layer, wherein the wear layer substantially overlies the tie layer such that at least a portion of the second surface of the wear layer contacts and adheres to at least a portion of the first surface of the tie layer.
The method of making the resilient floor coverings described herein further comprises applying the second surface of the decorative portion onto the first surface of the backing portion. The method of making the resilient floor coverings described herein further comprises applying the second surface of the tie layer as described herein onto the first surface of the decorative portion such that the second surface of the tie layer contacts and adheres to the first surface of the UV cured ink layer. The method of making the resilient floor coverings described herein further comprises applying the second surface of the wear layer onto the first surface of the tie layer such that the second surface of the wear layer contacts and adheres to the first surface of the tie layer.
The method of making the resilient floor coverings described herein further comprises applying a first surface of the tie layer as described herein on the second surface of the wear layer such that the first surface of the tie layer contacts and adheres to the second surface of the wear layer. The method of making the resilient floor coverings described herein further comprises applying the first surface of the decorative portion on the second surface of the tie layer such that the first surface of the decorative portion contacts and adheres to the second surface of the tie layer. It is further understood that in the aspects, wherein the first surface of the UV cured ink layer defines the first surface of the decorative portion, the first surface of the UV cured ink layer adheres to the second surface of the tie layer.
It is further understood that the method of making the resilient floor coverings described herein can further comprise first applying a first surface of the tie layer as described herein on the second surface of the wear layer such that the first surface of the tie layer contacts and adheres to the second surface of the wear layer. Then, the first surface of the decorative portion can be applied on the second surface of the tie layer such that the first surface of the decorative portion contacts and adheres to the second surface of the tie layer. It is further understood that since the first surface of the UV cured ink layer defines the first surface of the decorative portion, the first surface of the UV cured ink layer adheres to the second surface of the tie layer. And then, the backing portion is applied to the decorative portion.
The method of making the resilient floor coverings described herein can further comprise applying an additional tie layer thereto the top surface of the backing portion. In that case, the method of making the resilient floor coverings described herein can further comprise applying the decorative portion thereto the additional tie layer applied to the backing portion. It is contemplated that the second surface of the decorative portion can be substantially directly applied to the first surface of the backing portion or the additional tie layer applied thereto the backing portion. It is also contemplated that the second surface of the decorative portion can be applied to the first surface of the backing portion, or the additional tie layer applied thereto the backing portion, using a chemical adhesive, mechanical connection, or other application means. It is further understood that any additional tie layers used to bond or connect various portions of the described resilient floor coverings can be the same or different as the tie layer used to bond the wear layer and the UV cured ink layer as described herein.
In some other aspects, the method of making the resilient floor coverings described herein can further comprise a step of applying the second surface of the decorative portion onto the first surface of the backing portion comprising: printing a digital image on a substrate layer to form an ink layer comprising a UV curable ink, wherein the substrate layer is present in the decorative portion and wherein the substrate layer has a first surface and a second surface, wherein the second surface of the substrate layer is opposed to the first surface of the substrate layer, wherein the ink layer is formed on the first surface of the substrate, and wherein the second surface of the substrate layer is the second surface of the decorative portion, and curing the UV curable ink to form the UV cured ink layer.
The method of making the resilient floor coverings described herein can further comprise first a step of printing a digital image on a substrate layer to form an ink layer comprising a UV curable ink, wherein the substrate layer is present in the decorative portion and wherein the substrate layer has a first surface and a second surface, wherein the second surface of the substrate layer is opposed to the first surface of the substrate layer, wherein the ink layer is formed on the first surface of the substrate, and wherein the second surface of the substrate layer is the second surface of the decorative portion, and then applying the second surface of the decorative portion onto the first surface of the backing portion, and curing the UV curable ink to form the UV cured ink layer.
The method of making the resilient floor coverings described herein further comprises applying the tie layer thereto the first surface of the decorative portion. The first surface of the decorative portion is defined by the UV cured ink layer. It is understood that the tie layer used herein can comprise one or more tie layers that are applied thereto the first surface of the decorative portion.
The method of making the resilient floor coverings described herein further comprises applying the wear layer thereto the first surface of the tie layer that is applied to the first surface of the decorative portion. The first surface of the wear layer can be exposed to an ambient environment. The method of making the resilient floor coverings described herein can further comprise applying a scratch layer to the first surface of the wear layer.
It is further understood that alternatively, the first surface of tie layer is first applied thereto the second surface of the wear layer. In certain examples, the wear layer comprises the scratch layer. In other examples, the wear layer does not comprise the scratch layer. It is understood that the tie layer used herein can comprise one or more tie layers that are applied thereto the second surface of the wear layer. Further, the decorative portion alone or combined with the backing portion can be applied thereto the second surface of the tie layer.
It is understood that digitally printed UV curable inks can comprise any UV-curable inks known in the art and described herein. It is further understood that after digitally printing the image onto the substrate, the inks are UV-cured. In some aspects, the curing process comprises one step. This type of curing process is known in the industry as an A-stage curing. In yet other aspects the curing process comprises a number of steps. In certain aspects, the curing process can comprise a first step and a second step. This type of curing process is known in the industry as a B-stage curing. The first step of the curing process can be applied to the ink layer printed on the substrate at a curing energy lower than a curing energy usually utilized in A-stage curing processes. The energy used in the first step of the B-stage curing process can be about 1/2 of the energy used in the A-stage curing process. The first step of the B-stage curing process can produce a partially cured ink layer. In some examples, the tie layer can be applied to this partially cured ink layer, and then a second step of the B-stage curing process is performed. In some examples, the tie layer can be applied to the partially cured ink layer followed by application of the wear layer, and only then the second step of the B-stage curing process is performed.
The tie layers described herein comprise an adhesive composition comprising a hot melt polyurethane.
The disclosed layers of the resilient floors covering can be constructed or otherwise formed by conventional methods and/or processes. Similarly, it is contemplated that the respective layers can be connected to each other in sequential or non-sequential order. Unless otherwise stated, no particular order of operative steps for product formation is required to practice the present invention. It is further contemplated that any conventional means of forming or joining layers of a layered construct such as the exemplified resilient floor covering can be used, to include, without limitation, extrusion, lamination, combinations of the same, and the like. Finally, it is contemplated that after the layers of the flooring covering are joined together, the resulting sheet of flooring composite can be cut into desired shapes and desired sizes, for example, and without limitation, into a roll goods, plank or tile shapes that can be conventionally or non-conventionally sized and/or shaped.
In one embodiment, the materials that are selected for the respective layers of the flooring covering can be readily recycled. It is contemplated that one or more of the respective layers can comprise recycled post-consumer and/or post-industrial materials, such as, for example and without limitation, recycled post-industrial carpet and/or post-consumer carpet polymeric materials. The formed floor covering can minimize use of virgin materials and advantageously allow for the use of previously recycled materials in forming the recyclable flooring covering of the present invention.
A first backing layer can be extruded thereon or otherwise connected to the second surface of the substrate and a fiberglass mat layer is imbedded therein the second surface of the first backing layer. Of course, prior to this step, an optionally additional tie layer can be connected to the second surface of substrate layer if required.
The applying of the tie layer can be done by any methods known in the art. In some aspects, the tie layer can be extruded or casted. It might be deposited using slot dies, or hotmelts, or any combination thereof. For example, the tie layer can be melted and cast through a sheet die, and then a desired amount of the material is applied to the UV cured ink layer, or any other desirable layer. After coating the film with the extrusion process, the material can be quenched or set with a typical cooling process, such as cooling rolls, prior to the coated film being re-rolled. The tie layer is in the form of a liquid hot melt polyurethane adhesive, and can be added onto the UV cured ink layer, the wear layer, or any other layer by a spray or roll-coating process. As would be recognized by one of skill in the art, the tie layer can be applied to the UV cured ink layer or any other layer while in liquid form by spray equipment or roll-coating equipment, and then dried with heat, air, or other curing means prior to re-rolling the film.
A second backing layer can be extruded thereon or otherwise connected to the bottom surface of the fiberglass mat layer to fully encapsulate the fiberglass layer. Referring to FIG.2 , in one example, the respective first backing layer and second backing layer can comprise the backing composition described herein. Next, if desired, a secondary backing, such as the exemplified non-woven polypropylene secondary backing, can be extruded thereon or otherwise connected to the bottom surface of the second backing layer.
In some aspects, initially the UV cured ink layer is applied to the first surface of the substrate layer. Sequentially, the backing portion comprising any disclosed layers is applied to the second surface of the substrate layer that defines the second surface of the decorative portion. Next, sequentially, the tie layer is applied to the UV cured ink layer and the wear layer is applied to the first surface of the tie layer. The step of applying the tie layer to the UV cured ink layer and then applying the wear layer to the tie layer can be done, for example, sequentially in a co-extrusion process.
In some aspects, initially the UV cured ink layer is applied to the first surface of the substrate layer. Sequentially, the backing portion comprising any disclosed layers is applied to the second surface of the substrate layer that defines the second surface of the decorative portion. Next, sequentially, the tie layer is applied to the wear layer and the decorative portion is applied to the second surface of the tie layer.
Each layer or portion of the resilient flooring can be manufactured or laminated together using traditional manufacturing methods, such as, but not limited to, a static press. As would be recognized by one of skill in the art, the method used for lamination in a static press would include the use of heat and pressure between metal plates for a specified amount of time to press together each of the desired layers described herein. For example, and without limitation, a combination of the wear layer, tie layer(s), UV cured ink layer, substrate layer, optional additional tie layer(s), and one or more backing layers, would be stacked in the desired order and placed inside the static press, then laminated together with the aforementioned combination of heat and pressure. One or more of the metal plates used to press the layers or portions of the resilient flooring together may include an emboss texture to transfer to the top or bottom surface of the resilient flooring. This emboss texture could include a design desired for the wear layer that is inherent in the final product.
Each individual layer or portion of the resilient floor covering can be independently manufactured prior to the production of the resilient floor covering. For example, and referring now to the particular example illustrated in FIG. 3 , an exemplary system for producing backing layer is shown. Here, the backing composition, which optionally can include a tackifier, recycled content, and/or chopped fiberglass is compounded (310), extruded (312), and rolled through a calendar (314)to form backing layer. The formed backing layer is then wound by the core winder (316) into rolls, which can later be used to produce the disclosed resilient floor coverings.
Referring now to the particular example illustrated in FIG. 4 , an exemplary system for producing the floor covering is shown. The resilient floor covering can be prepared by a nip roll methods, for example, by applying the layers off rolls using winders (420). The formed backing layer is rolled (402a) onto a top surface of a nip roll (422). Optionally, a secondary backing layer (402b) can first be unrolled onto the belt, next sequentially if the secondary backing layer is used. In the embodiments in which the backing layer of the backing portion comprises a first backing layer and a second backing layer, a fiberglass mat layer (402d) can be rolled thereon the first backing layer and, sequentially, the second backing layer is rolled thereon the fiberglass mat layer. In this example, the secondary backing layer defines the bottom surface of the backing portion and the first backing layer defines the top surface of the backing portion. Here, if a secondary backing layer is used, it is contemplated that the first and second backing layers are configured to substantially overlie the secondary backing layer. Infrared heaters (430) can be used in the process. Further, the decorative portion (404) and a wear layer (408) are rolled to form a textured (424) article that is then cut (426) to a desired size and stacked (428).
Referring now to the particular example illustrated in FIG. 5 , an exemplary system for adhering the decorative portion and the wear layer is shown. The wear layer (508) is unrolled onto a top surface of a nip roll, the tie layer (506),comprising an adhesive composition comprising a hot melt polyurethane, is applied onto the wear layer. In this example, the decorative portion (504) comprising the UV cured ink layer is unrolled on the second surface of the tie layer. It is understood that in this example, the decorative portion can be applied alone, or can be previously combined with the backing portion. Sequentially, all three layers are laminated by passing through NIP roller (512) and rolled at a rewind station (510).
Referring now to the particular example illustrated in FIG. 6 , an exemplary system for adhering the decorative portion and the wear layer is shown. In one aspect, the decorative portion comprising the ink layer (604) is unrolled onto a top surface of a nip roll, the tie layer (606), comprising an adhesive composition comprising a hot melt polyurethane, is applied onto the first surface of the decorative portion comprising the ink layer. In this example, the wear layer (608) is unrolled on the first surface of the tie layer. Sequentially all three layers are laminated by passing through NIP roller (612), cured by UV-light (614) and rolled at a rewind station (610).
In a next step, a decorative portion and a wear layer are first attached to each other by a tie layer described herein, and then are rolled thereon the backing portion and the flooring product is optionally passed therebetween a pair of opposed rollers to emboss the flooring product as desired prior to the flooring product being cut to a desired size and/or shape, and stacked. In a further example, each rolled layer can be optionally operatively heated using an infrared heater or dryer.
In a further aspect, the edge profile can have any desired edge profile design, for example and without limitation, a click-lock or tongue and groove connection system. In some aspects, the edge profile for connecting can have a more complex geometry. In a further example, the edge connection system can substantially restrict movement from side-to-side and vertically. In a still further example, the connection seams, once installed, are all uniform and flat at each connection point. In a yet further example, the edge profile can be different for all four edges.
In a further example, the edge profile can be formed by any desired means, for example, by milling, routing or tenoner process, or the like.
As one of skill in the art will recognize, the backing composition formulation can influence the stability of the backing portion, for example, the relative amounts and types of filler and polyolefin elastomer used in the formulation. In a further example, additives, such as tackifiers, foaming agents, process aids, and plasticizers can also influence the stability of the formulation. In a still further example, an unstable backing portion can have weak edge connection profiles that can be easily damaged. In a yet further example, smoothness and uniformity of the edge connection profile can be influenced by the backing composition formulation. In an even further example, the wear layer and scratch layer can delaminate, melt, or flake off during the edge profile process or when the flooring is installed.
The resilient floor coverings of the present invention advantageously do not exhibit flaking, melting, or delamination during the edge profiling process. In a further example, the disclosed resilient floor coverings do not exhibit brittle or weak edge connection profiles.
The following examples are put forth so as to provide those of ordinary skill in the art with a complete disclosure and description of how the compounds, compositions, articles, devices and/or methods claimed herein are made and evaluated,

EXAMPLES

Example 1:

In this Example, a resilient floor covering sample was prepared using a conventional backing portion. The decorative portion was prepared by digitally printing Durst 30 DM ink (a UV-cured ink) on a 3 mil (76µm) thickness whitened PVC film used a substrate layer. The ink was cured according to the known in the art UV curing methods. A 1 mil (25µm) tie layer of Technomelt^® PUR 475A hot melt (a hot melt polyurethane adhesive available from Henkel) was deposited on a surface of the cured ink and a clear 12 mil (300µm) thickness PVC film was then deposited as a wear layer on the underlying tie layer. A UV cured scratch layer was further applied to the wear layer. The sample was tested for pull resistance. It was determined that the wear layer exhibited pull values greater than about 3 pounds (1.4kg) as determined by ASTM 3936 with 1" (2.5cm) by 6" (15cm) strip pulled at a rate of 2"/min (5.1 cm/min) for a pull distance of 2" (5.1cm).

Claims

A resilient floor covering, such as a rolled good, a tile, or a plank, comprising:
a backing portion (102; 202) having a first surface and a second surface, wherein the second surface of the backing portion is opposed to the first surface of the backing portion, wherein the backing portion comprises at least one backing layer (202a, 202b, 202c, 202d),

a decorative portion (104; 204) having a first surface and a second surface, wherein the second surface of the decorative portion is opposed to the first surface of the decorative portion, wherein the decorative portion overlies the backing portion such that at least a portion of the second surface of the decorative portion contacts at least a portion of the first surface of the backing portion, wherein the decorative portion comprises a UV cured ink layer (204b), and wherein the UV cured ink layer has a first surface and a second surface, and wherein the second surface of the UV cured ink layer is opposed to the first surface of the UV cured ink layer, and wherein at least a portion of the first surface of the UV cured ink layer defines at least a portion of the first surface of the decorative portion;

a tie layer (106; 206) comprising an adhesive composition comprising a hot melt polyurethane and having a first surface and a second surface, wherein the second surface of the tie layer is opposed to the first surface of the tie layer, wherein the tie layer substantially overlies the decorative portion such that at least a portion of the second surface of the tie layer contacts and adheres to the first surface of the UV cured ink layer; and

a wear layer (108; 208) having a first surface and a second surface, wherein the second surface of the wear layer is opposed to the first surface of the wear layer, wherein the wear layer substantially overlies the tie layer such that at least a portion of the second surface of the wear layer contacts and adheres to at least a portion of the first surface of the tie layer.
The resilient floor covering of claim 1, wherein the UV cured ink layer (204b) comprises digitally printed ink.
The resilient floor covering of claim 1 or 2, wherein the UV cured ink layer (204b) is not a continuous layer.
The resilient floor covering of any one of claims 1-3, wherein the decorative portion (104; 204) further comprises a substrate layer (204a) having a first surface and a second surface, wherein the second surface of the substrate layer is opposed to the first surface of the substrate layer, and wherein the UV cured ink layer (204b) is applied to the first layer of the substrate layer.
The resilient floor covering of claim 4, wherein the second surface of the substrate layer (204a) is the second surface of the decorative portion (104; 204) overlying the first surface of the backing layer.
The resilient floor covering of any one of claims 4 or 5, wherein the substrate layer (204a) comprises at least one of polyvinyl chloride (PVC), whitened PVC, opaque PVC, oriented polypropylene (OPP), polyolefin (PO), woven polyethylene (PE), nonwoven PE, woven polypropylene (PP), nonwoven PP, woven PET, nonwoven PET, woven nylon, nonwoven nylon, conventional papers, conventional foils, or foiled oriented polypropylene.
The resilient floor covering of any one of claims 4-6, wherein the substrate layer (204a) comprises one or more of heat stabilized biaxially-oriented PET (BoPET), amorphous PET (aPET), recycled PET (rPET), polyethylene terephthalate glycol-modified (PETG), polyolefin, cyclic olefin copolymer (COC), cyclic olefin polymer (COP), polyvinylidene fluoride (PVDF), polylactic acid (PLA) copolymers, nylon, cellulose acetate, poly(methyl methacrylate) (PMMA), thermoplastic polyurethane (TPU), thermoplastic elastomers (TPS), polycarbonate, polyethylene (PE), or a copolymer thereof.
The resilient floor covering of any one of claims 4-7, wherein the substrate layer (204a) has a thickness from about 1 mil (25µm) to about 8 mil (200µm).
The resilient floor covering of any one of claims 4-8, wherein the substrate layer (204a) is a film.
The resilient floor covering of any one of claims 1-9, wherein the tie layer (106; 206) has a thickness of about 0.5 mil (13µm) to about 4 mil (100µm).
The resilient floor covering any one of claims 1-10, wherein the wear layer (108; 208) is a substantially transparent layer.
The resilient floor covering of any one of claims 1-11, wherein the wear layer (108; 208) comprises at least one of polyethylene terephthalate (PET), glycol-modified polyethylene terephthalate (PETG), polyurethane, polypropylene, polytrimethylene terephthalate (PTT), polyvinyl chloride (PVC), Nylon 6, or Nylon 6,6.
The resilient floor covering of any one of claims 1-12, wherein the wear layer (108; 208) comprises at least one of: heat stabilized biaxially-oriented PET (BoPET), amorphous PET (aPET), recycled PET (rPET), polyolefin, cyclic olefin copolymer (COC), cyclic olefin polymer (COP), polyvinylidene fluoride (PVDF), polylactic acid (PLA) copolymers, nylon, cellulose acetate, poly(methyl methacrylate) (PMMA), thermoplastic polyurethane (TPU), thermoplastic elastomers (TPS), polycarbonate, polyethylene (PE), or a copolymer thereof.
The resilient floor covering of any one of claims 1-13, wherein the wear layer (108; 208) has a thickness of from about 4 mil (100µm) to about 30 mil (760µm).
The resilient floor covering of any one of claims 1-14, wherein the resilient floor covering further comprises a scratch layer, preferably a UV cured scratch layer, having a first surface and a second surface, and wherein the scratch layer overlies the wear layer (108; 208) such that at least a portion of the second surface of the scratch layer contacts at least a portion of the first surface of the wear layer.
A method for making a resilient floor covering such as a rolled good, a tile, or a plank, comprising:
forming a composite comprising:
a backing portion (102; 202) having a first surface and a second surface, wherein the second surface of the backing portion is opposed to the first surface of the backing portion, wherein the backing portion comprises at least one backing layer (202a, 202b, 202c, 202d),

a decorative portion (104; 204) having a first surface and a second surface, wherein the second surface of the decorative portion is opposed to the first surface of the decorative portion, wherein the decorative portion overlies the backing portion such that at least a portion of the second surface of the decorative portion contacts at least a portion of the first surface of the backing portion, wherein the decorative portion comprises a UV cured ink layer (204b), and wherein the UV cured ink layer has a first surface and a second surface, and wherein the second surface of the UV cured ink layer is opposed to the first surface of the UV cured ink layer, and wherein at least a portion of the first surface of the UV cured ink layer defines at least a portion of the first surface of the decorative portion;

a tie layer (106; 206) comprising an adhesive composition comprising a hot melt polyurethane and having a first surface and a second surface, wherein the second surface of the tie layer is opposed to the first surface of the tie layer, wherein the tie layer substantially overlies the decorative portion such that at least a portion of the second surface of the tie layer contacts and adheres to the first surface of the UV cured ink layer; and

a wear layer (108; 208) having a first surface and a second surface, wherein the second surface of the wear layer is opposed to the first surface of the wear layer, wherein the wear layer substantially overlies the tie layer such that at least a portion of the second surface of the wear layer contacts and

adheres to at least a portion of the first surface of the tie layer;
and wherein the step of forming comprises:
applying the second surface of the decorative portion onto the first surface of the backing portion;

applying the second surface of the tie layer onto the first surface of the decorative portion such that the second surface of the tie layer contacts and adheres to the first surface of the UV cured ink layer; and

applying the second surface of the wear layer onto the first surface of the tie layer such that the second surface of the wear layer contacts and adheres to the first surface of the tie layer;

preferably wherein the step of applying the second surface of the decorative portion onto the first surface of the backing portion further comprises:
printing a digital image on a substrate layer (204a) to form an ink layer comprising a UV curable ink, wherein the substrate layer is present in the decorative portion and wherein the substrate layer has a first surface and a second surface, wherein the second surface of the substrate layer is opposed to the first surface of the substrate layer, wherein the ink layer is formed on the first surface of the substrate, and wherein the second surface of the substrate layer is the second surface of the decorative portion, and
curing the UV curable ink to form the UV cured ink layer.
The method of claim 16, wherein a step of curing comprises one step or two or more steps .
The method of claim 16 or 17, wherein the step of applying the tie layer (106; 206) comprises extruding the tie layer onto the decorative portion (104; 204).
The method of any one of claims 16-18, further comprising applying a scratch layer, preferably a UV cured scratch coat, on the composite, wherein the scratch layer has a first surface and a second surface and overlies on the wear layer (108; 208) such that the second surface of the scratch layer contacts the first surface of the wear layer.